Casingless food production methods, systems, and associated traveling matable mold shells

ABSTRACT

Systems, methods, and associated devices for casingless production of food products include: (a) providing a series of shells, the shells having sufficient structural rigidity to define an enclosed cavity space of predetermined substantially constant size and shape; (b) injecting a quantity of flowable food emulsion into the shells in serial order; (c) moving the shells forward along a predetermined travel path with the emulsion in the enclosed cavities; (d) exposing the emulsion in the shells to predetermined processing conditions that alter the emulsion held in the respective shells to a non-flowable edible food product having the molded shape of their respective shell cavities; and then (e) releasing the non-flowable food products from their respective shells.

FIELD OF THE INVENTION

[0001] The present invention relates to the casingless production offood product.

BACKGROUND OF THE INVENTION

[0002] Conventionally, natural or artificial casings can be used to formand hold food products to help hold the shape and/or retain contentintegrity during processing, such as cooking, heating, or freezing. Thefood product can start as a flowable emulsion that can be stuffed intothe casing or the casing can be formed around the emulsion by employinga co-extrusion process using a stuffer, extruder, or the like. Thecasing itself may be disposable and removed from the food product priorto shipping and/or eating or may remain intact on the food productduring consumption and ingested.

[0003] Known extruders and co-extruders are available from variouscommercial manufacturers including, but not limited to, the Kontura fromTownsend Engineering Co., located in Des Moines, Iowa. Stuffers areavailable from various commercial manufacturers including, but notlimited to, HITEC Food Equipment, Inc., located in Elk Grove Village,Ill., Townsend Engineering Co., located in Des Moines, Iowa, RobertReiser & Co., Inc., located in Canton, Mass., and Handtmann, Inc.,located in Buffalo Grove, Ill. Exemplary stuffer and/or linker apparatusare also described in U.S. Pat. Nos. 5,788,563; 5,480,346; 5,049,108;and 4,766,645. The contents of these patents are hereby incorporated byreference as if recited in full herein.

[0004] However, there remains a need to provide cost-effective automatedcasingless processing systems of food items.

SUMMARY OF THE INVENTION

[0005] The present invention provides casingless food production systemsand methods. The term “casingless” means that the food product can beproduced without requiring the assistance of a holding skin such as acollagen or natural skin casing. The term encompasses food items thatare conventionally produced using casings (such as hot dogs and sausagesand the like), as well as food items that have not required the use ofcasings (meatballs, popsicles, baked goods, shaped burgers, and thelike).

[0006] In certain embodiments, the methods and systems are configured toprovide casingless lengths of food product using endless travel matablemold shells. The food product can be configured to enter the matablemold shells as a flowable emulsion that is held encased in the matablemold shells while the mold shells and the product held therein travelalong a predetermined travel path.

[0007] In operation, as the product and shell move forward, the productis exposed to predetermined processing conditions that alter thephysical form of the emulsion to a non-flowable state. The change in thephysical state can be chemically or thermally initiated. Over time, theproduct can take on the shape of the matable mold shell with sufficientstructural rigidity so that it is able to retain that shape withoutsubstantial deformation after its release therefrom. As such, in certainembodiments, the released food item may be compressible (semi-solid andyielding to tactile compression forces) or substantially incompressible(frozen or solid) at ambient conditions.

[0008] The food may be elongated and regularly shaped (in an elongatedor substantially cylindrically configuration) or may be non-elongatedand irregularly shaped. The food may be cooked, frozen, smoked, cured,pickled, partially dehydrated, or otherwise processed as it movesthrough the processing region.

[0009] Systems, methods, and associated devices for casinglessproduction of food products include: (a) providing a series of shells,the shells having sufficient structural rigidity to define an enclosedcavity space of predetermined substantially constant size and shape; (b)injecting a quantity of flowable food emulsion into the shells in serialorder; (c) moving the shells forward along a predetermined travel pathwith the emulsion in the enclosed cavities; (d) exposing the emulsion inthe shells to predetermined processing conditions that alter theemulsion held in the respective shells to a non-flowable edible foodproduct having the molded shape of their respective shell cavities; andthen (e) releasing the non-flowable food products from their respectiveshells.

[0010] Other embodiments are directed to casingless food productionsystems. The systems include: (a) a plurality of shells arranged in anendless travel path, the shells configured with at least one emulsionentry port and first and second detachably matable shell portions, theshell portions are configured to matably attach together to provide anenclosed cavity having a predetermined configuration, and to part toallow access to the interior of the cavity; (b) a flowable food emulsionsource comprising a flow nozzle that is configured to serially flowablyinput a quantity of emulsion into the shells; (c) a transport systemthat is configured to move the plurality of shells along the endlesstravel path so that each shell is positioned in cooperating alignmentwith the food emulsion source at least once during each cycle of travelalong the endless travel path; and (d) a processing region operablyassociated with the endless travel path so that, in operation, theprocessing region exposes the emulsion in the attached shells to apredetermined energy as the shells travel along a portion of the endlesstravel path.

[0011] Other embodiments are directed to casingless food productionsystems that include: (a) means for providing a series of alignedshells, the shells having sufficient structural rigidity to define anenclosed cavity space of predetermined size and shape; (b) means forinjecting in serial order a quantity of flowable food emulsion into theshells; (c) means for moving the shells forward along a predeterminedtravel path with the emulsion in the enclosed cavities; (d) means forexposing the emulsion in the shells to predetermined processingconditions; (e) means for altering the physical form of the emulsionheld in the respective shells to a non-flowable edible food product; (f)means for molding the emulsion in the shells so that the released foodproducts have the shape of their respective shell cavity; and then (g)means for releasing the non-flowable food products from their respectiveshells.

[0012] Still other embodiments are directed to mold assemblies for theproduction of foodstuffs. The assemblies include: (a) a first moldportion having a first inner cavity region; (b)a second mold portionhaving a second inner cavity region, the first and second mold portionsbeing detachably matable theretogether so that the first and secondinner cavity regions align to define a mold cavity having apredetermined three dimensional foodstuff mold shape; and (c) atransport system operably associated with the first and second moldportions that automatically moves the first and second mold portions inrespective endless paths that allows the first and second mold portionsto matably attach and then detach as they travel along their respectiveendless paths.

[0013] These and other objects and aspects of the present invention areexplained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1A is a schematic side view of a casingless foodstuffproduction system employing traveling molds according to embodiments ofthe present invention.

[0015]FIG. 1B is a schematic side view of a casingless productionsystem, the molds thereof having an extended travel path over theembodiment shown in FIG. 1A according to other embodiments of thepresent invention.

[0016]FIG. 1C is a schematic side view of a casingless productionsystem, the molds thereof having an extended travel path over theembodiments shown in FIGS. 1A and 1B according to additional embodimentsof the present invention.

[0017]FIG. 1D is a schematic perspective view of a casingless productionsystem employing traveling molds according to alternate embodiments ofthe present invention.

[0018]FIG. 2A is a side perspective view of a portion of a travelingmold arrangement according to embodiments of the present invention.

[0019]FIG. 2B is a front sectional view taken along line 2B-2B in FIG.2A.

[0020]FIG. 3A is an end perspective view of a portion of a travelingmold arrangement according to embodiments of the present invention

[0021]FIG. 3B is a front section view taken along line 3B-3B in FIG. 3A.

[0022]FIG. 4A is a side view of one side of a mold with an irregularlyshaped, side profile, three-dimensional mold cavity according toembodiments of the present invention.

[0023]FIG. 4B is a side view of one side of a mold with an irregularlyshaped, side profile, three-dimensional mold cavity that can moldmultiple distinct foodstuff items in a single mold according toembodiments of the present invention.

[0024]FIG. 4C is a side view of one side of two adjacent molds (togetherthe two adjacent molds forming an object with an irregular shaped sideprofile), the object occupying the adjacent complementary mold cavityspaces to provide the desired three-dimensional mold cavity according toembodiments of the present invention.

[0025] FIGS. 5A-5E are front cross-sectional views of mold cavity shapesconfigured to provide non-customary cross-sectional profiles accordingto embodiments of the present invention. The same figures can alsoillustrate side profile views of the cavities, as desired. For example,the mold cavity may be configured to have a variable cross-sectionalvolume, front to back and side to side, to mold the foodstuff into adesired object shape (such as the football shown in FIG. 5E).

[0026]FIG. 6A is a side view of a portion of the inside of a mold cavityhaving surface indicia recessed into the inner wall or surface thereofaccording to embodiments of the present invention.

[0027]FIG. 6B is a side view of a portion of the inside of a mold cavityhaving raised surface indicia on the inner wall or surface thereofaccording to embodiments of the present invention.

[0028]FIGS. 7A and 7B are schematic illustrations of examples ofalterations in the physical state or consistency of the emulsion held inthe shell as it travels along the food travel path according toembodiments of the present invention.

[0029]FIG. 8 is a schematic illustration similar to FIGS. 7A and 7Billustrating that a cooling source may be used in the processing regionto facilitate the molding or alteration of the flowable emulsion to anon-flowable molded shape.

[0030]FIG. 9A illustrates three different exemplary processingconditions along a food travel path according to embodiments of thepresent invention.

[0031] FIGS. 9B-9E are graphs of profiles of processing temperature as afunction of time for the system of FIG. 9A according to embodiments ofthe present invention.

[0032]FIG. 10A is a schematic illustration of a dual line processingsystem according to embodiments of the present invention.

[0033]FIG. 10B is an enlarged end section view of the dual line moldassembly shown in FIG. 10A.

[0034]FIG. 10C is a schematic illustration of a dual line processingsystem similar to that shown in FIG. 10A, but showing a vertical foodtravel path, according to embodiments of the present invention.

[0035]FIG. 11A is a schematic illustration of a cooperating nestedarrangement of traveling molds for a plurality of production lines in aprocessing system according to embodiments of the present invention.

[0036]FIG. 11B is an enlarged end cross-sectional view of thecooperating molds in the production lines shown in FIG. 11A.

[0037]FIG. 11C is a schematic illustration of a processing systemsimilar to that shown in FIG. 11A, but showing vertical food travelpaths according to embodiments of the present invention.

[0038]FIG. 12A is a schematic of a closed mold shell with a centerparting line according to embodiments of the invention. FIGS. 12B and12C illustrate exemplary connections that allow separation of the twomold halves shown in FIG. 12A. The mold cavity can be oriented to openin an upward direction as shown.

[0039]FIG. 13A is a schematic of a closed mold shell with a centerparting line according to embodiments of the invention. FIGS. 13B and13C illustrate exemplary connections that allow separation of the twomold halves shown in FIG. 13A. The mold cavity can be oriented to openin a downward direction as shown.

[0040] FIGS. 14A-14B are schematic illustrations of a multiple componentmold shell that employs greater than two mating components according tocertain embodiments of the present invention.

[0041] FIGS. 15A-15B are schematic illustrations of a multiple componentmold shell that employs greater than two mating components according tocertain embodiments of the present invention.

[0042] FIGS. 16A-16C are schematic illustrations of examples of matingalignments of mold components to define the enclosed cavity according toembodiments of the present invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0043] The present invention will now be described more fullyhereinafter with reference to the accompanying figures, in whichembodiments of the invention are shown. This invention may, however, beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein. Like numbers refer to like elementsthroughout. In the figures, certain layers, components or features maybe exaggerated for clarity, and broken lines illustrate optionalfeatures or operations unless specified otherwise. In addition, thesequence of operations (or steps) is not limited to the order presentedin the claims unless specifically indicated otherwise.

[0044] In the description of the present invention that follows, certainterms are employed to refer to the positional relationship of certainstructures relative to other structures. As used herein, the term“forward” and derivatives thereof refer to the general or primarydirection that food travels as it moves inside a food processor from aprocessing point or region to the next processing point or region; thisterm is intended to be synonymous with the term “downstream,” which isoften used in manufacturing environments to indicate that certainmaterial being acted upon is farther along in the manufacturing processthan other material. Conversely, the terms “rearward” and “upstream” andderivatives thereof refer to the directions opposite, respectively, theforward and downstream directions.

[0045] The present invention may be particularly suitable to producefood items such as, but not limited to, elastic or partially elasticfood items such as meat products, cheese (e.g., mozzarella strands), ordough. In certain embodiments, the food products are whole or partialmeat mixtures that include a single or multiple different types of meatincluding, but not limited to, beef, poultry, lamb, veal, and porkincluding derivatives and/or meat analogs of selected ones orcombinations of the meat. Other animal, poultry, fish, or desired meatsmay also be employed where desired. The meat based food products may bemeat sticks or strands, elongate meat products such as hot dogs,sausages (of any type including Vienna sausage (typically a beef, pork,and veal emulsion blend)), and the like. In other embodiments, the foodproducts need not be elongate and can be candy and/or frozen dessertsnack treats such as ice cream, yogurt, popsicles, and the like.

[0046] Generally described, in certain embodiments, the product isproduced by introducing (typically injecting) under pressure a flowablefood material(s) into the cavity of a shell (or mold) that is configuredto encase the material. The terms “shell” and “mold” are usedinterchangeably herein. The flowable material can be configured as anemulsion or slurry of a single major constituent and a liquid (such aswater or other food compatible liquid) or an emulsion or slurry mixtureof several different major constituents. “Major” as used herein meansthat the constituent is present as a primary constituent typically as atleast 10% of the volume of the emulsion or slurry. As the shell (whichdefines the mold cavity) with the encased food material travels forwardalong its selected travel path, the encased material alters to anon-flowable state and takes on the shape defined by the cavity of theshell. In certain embodiments, the product is exposed to predeterminedprocessing conditions that alter the physical form of a flowableemulsion to a non-flowable state. The processing conditions can includeone or more of thermal energy (hot or cold), microwave energy, RFenergy, UV light, laser energy, and the like.

[0047] In certain embodiments, the change in the physical state can bechemically or thermally initiated. In particular embodiments, certain ofthe constituent ingredients may be chosen so that when combined andexposed to a predetermined activation condition, such as heat, theyreact to yield a desired change in the physical state or a desiredchange in the food value. Over time, the chemical or thermal initiatedreaction can cause the product to harden or become more viscous andnon-flowable and form into the shape of the matable mold shell. Uponrelease, the product has the shape of the mold cavity. As such, incertain embodiments, the released food item may be compressible(semi-solid and yielding to tactile compression forces) or substantiallyincompressible (frozen or solid) at ambient conditions. The shell ormold itself is configured with sufficient structural rigidity so that itis able to define the cavity without the emulsion held therein and toresist deformation when the emulsion is injected into the cavity underpressure in sufficient amount and force to cause the product to fill thecavity.

[0048] In certain embodiments, the flowable emulsion may be a meatproduct emulsion that can include additives, flavorings, vegetables,fruits, spices, or other edible biocompatible constituents. Someconstituents of the flowable emulsion may include fluids, such asliquids, solid particulates of various sizes, and ground, shredded,segmented or otherwise processed meat, meat analogs, or derivativesthereof. In certain embodiments, the emulsion can be viscous, while inothers it may be semi-viscous and/or substantially inviscid at theinitiation of the process (such as at introduction into the shell).Thus, the systems contemplated by the present invention may be used toprocess food products in a wide variety of density ranges (low to high),such as water (to ice), fluffed creams, meat or meat analog slurries,and the like.

[0049] The emulsion can be selected to yield elongated food itemsincluding, but not limited to, hot dogs, sausages, and the like. The enditem may be elastic so as to allow some stretching without undulyaltering or deforming its desired shape (from that of the mold shape)after release from the mold cavity of the shell during processing.Alternatively, the emulsion and mold shells may be formulated so thatdiscrete non-elongated products such as shaped meatballs and other foodproducts may be produced.

[0050] In particular embodiments, after the product exits the moldcavity, or as it travels in the mold cavity, the product can be coatedwith a desired edible surface coating, such as, but not limited to,sugar, chocolate, candy sprinkles, and the like for sweet or dessertproducts or corn meal for corndogs, flour or other edible coating forother food products. The coating may be aerosolized, sprayed, orotherwise deposited onto all or selected exterior surfaces of theproduct.

[0051] Turning now to FIG. 1A, one embodiment of a casingless foodproduction system 10 is shown. As shown, the system 10 includes atraveling mold assembly 15, a processing region 20, and a flowablefoodstuff supply source 50S. The traveling mold assembly 15 includes aplurality of shells 15M₁-15Mn, that are defined by detachably matableshell portions 15A, 15B. The shell portions 15A, 15B are shown as shellhalves with an axially extending seam, but other configurations may alsobe employed. The circular shapes labeled as “A”, “B”, and “C” illustratean exemplary alteration in density or flowability of the food as ittravels along the food travel path. At location “A”, the product is aflowable emulsion, at location “B” some physical alteration has occurred(illustrated as a thicker density at the outermost portions of thefood), and at “C” the food has been processed so that it is of asubstantially constant consistency through its center (e.g., cooked).The exemplarly condition of the food at location “B” can vary dependingon the production exposure environments or thermal processingconditions. For example, RF or microwave thermal processing may resultin a different food density gradient. Other alteration patterns mayoccur depending on the desired processing result, the type of processingemployed, and the food being processed.

[0052] In the embodiment shown in FIGS. 1A-1C, the first and secondshell portions 15A, 15B are closely spaced end to end, about theirrespective endless paths. The system 10 or mold assembly 15 alsoincludes a transport system 15S that moves the shells 15A, 15B along apredetermined travel path. The transport system 15S can compriseconveyors, chains, cables, cords, or other drive means connected to adrive motor to move the shell portions 15A, 15B, individually and themated shells 15M together along the predetermined portions of the travelpaths. As shown, the transport system 15S comprises two separate drives16 ₁, 16 ₂, one for the first shell portion 15A and one for the secondshell portion 15B. The timing of the two drives 16 ₁, 16 ₂ can besynchronized so that the mated shell portions 15M that define the moldcavity move along in unison at a desired rate of speed.

[0053] Each corresponding portion of the shell 15A, 15B travels along arespective endless travel path, 15P₁, 15P₂. In advance of the emulsionloading station or food supply source 50S, corresponding pairs of theshells mate to define a molding cavity for the emulsion. The region inthe travel path at which the attachment is made is shown as location 1in FIGS. 1A-1C. Downstream of the first location 1, the mated shellportions part or separate into separate components at a second location,shown as location 2 in FIGS. 1A-1C, to release the food product 50 heldtherein which has transformed into a non-flowable product having theshape of the molding cavity. The shell portions 15A, 15B then travelseparately to be returned to location 1. As such, the food travel pathfor the food 50 is a subset of the shell travel path(s) 15P₁, 15P₂.FIGS. 1A-1C illustrate a few examples of the length of the travel paths15P₁, 15P₂, which may extend through one or a series of processingenvironments.

[0054] The processing region 20 can include different processingenvironments. By way of illustration, as shown in FIGS. 1A-1C, thesystem 10 includes three different processing regions 20A (shown as aheating zone), 20B (shown as a thermal holding zone), and 20C (shown asa cooling zone), each of which can present a different environment forthe food. The food 50 can travel encased in the mold cavity of thematably attached shell 15M throughout each processing region 20A, 20B,20C as shown in FIG. 1C, or can be released from the shell 15M at adesired region and processed independent of the shell after travelingthrough a major portion of one region 20A (FIG. 1A) or two regions 20A,20B (FIG. 1B).

[0055] In certain embodiments, the supply source 50S comprises aninjection nozzle 50N that is configured and positioned to be serially influid communication with the rearward portions of shells proximatelocation 1. The nozzle 50N can be dynamically operated to be seriallyinserted into and retracted from the mold cavities defined by the shells15M (or channels in fluid communication therewith) via an opening or atleast one filling port 17. Alternatively, the nozzle 50N may bestationary, and the shell portions 15A, 15B operated and positioned tofold or close about the nozzle 50N temporarily as they move forwardalong the travel path.

[0056] In certain embodiments, as shown in FIGS. 1A-1C, the filling port17 can be defined by a separation distance between the two shellportions 15A, 15B at a rearward portion of the respective shell portions15A, 15B as they travel toward each other to sealably attach. The speedof forward movement of the shell portions as well as the flow rate ofthe emulsion can be selected to inhibit the undue loss of product as thecavity closes relatively rapidly.

[0057] Each mated shell 15M may be configured, independently of othershells, to define its respective (sealed) mold cavity. In certainembodiments, the forward and rearward edges of each mated shell 15M canhave side, forward, and rear wall portions that sealably encase the moldcavity upon mating (not shown).

[0058] In other embodiments, adjacent pairs of shells 15M cooperate todefine the sealed cavity. For example, in particular embodiments,between adjacent pairs of the mated shells 15M, the rearward wallportion of a first mated shell 15M may have a port 17 formed thereinthat allows the nozzle 50N to reside temporarily therein to directemulsion into the corresponding inner mold cavity. In operation, theforward wall of the next adjacent rearwardly located shell can moveforward to close off the mold cavity port 17 of the shell locateddirectly in front thereof as the first mated shell 15M progress awayfrom the nozzle 50N to thereby inhibit undue leakage or flashing of theemulsion from its respective mold cavity. As such, the mold assembly 15may be configured so that the series of first and second shell portions15A, 15B, respectively are closely positioned and aligned so thatforward and rearward portions of adjacent mated shells 15M abut.

[0059] In yet other embodiments, the system 10 can be configured toprovide a food compatible sealant that covers the port 17 to inhibitemulsion leakage after filling to a desired pressure. In still otherembodiments, the nozzle 50N may be configured with a thermal probe thatis able to provide localized thermal energy (heat or cooling) atsufficient energy levels and temperature to the emulsion materialproximate the port after or during flowable filling to promote set-up orgelation thereat or to otherwise inhibit flow or leakage from the port17 to thereby inhibit spill or leakage. Still further, the filling maybe carried out with a valve that inhibits reverse flow. In particularembodiments, the filling can be carried out from a top portion of themated shell and with a flow path configuration that inhibits reverseflow.

[0060] In certain embodiments, the mold cavities or one of more of theshell portions 15A, 15B can be preheated or pre-cooled to cause theoutermost portion of the emulsion to gel relatively quickly in the moldcavity, thereby inhibiting excessive spill, flashing, or leakage fromthe mold cavity. Combinations of the filling and/or leak-inhibitingoperations described above may also be used.

[0061]FIG. 1D illustrates an alternate embodiment of a mold assembly 15′for a processing system 10. As before, the mold assembly 15′ comprises aplurality of matably attachable shell portions 15A, 15B that are drivenor moved along a predetermined travel path 15P. However, in thisembodiment, the shell portions 15A, 15B are hinged together and travelalong a common travel path 15P, in an open or closed (mated 15M)configuration. Similar to the embodiment shown in FIG. 1A, the matedshell 15M defines a mold cavity that holds a quantity of food therein.After the food 50 takes on the shape of the mold cavity and hasdeveloped sufficient rigidity to maintain that shape when releasedtherefrom, the shell 15M can be parted, separated, or opened (noted byfeature 15 s in FIG. 1D). Thus, the food alters from a flowable emulsionat location 1 to a non-flowable predetermined molded shape at location2. The shell can be configured to open about a top, bottom, or sideportion to release the food 50. The separation can be automaticallycarried out as the shell is traveling along the predetermined travelpath based on a clock or a trigger or sensor positioned in the travelpath that activates the initiation of the separation operation. Releasemembers can force the shell portions 15A, 15B open, or locks holding thebody closed can be released (not shown). As shown, in particularembodiments, the shell can open about a top hinged portion to flareoutwardly and release the product 50 with the aid of gravity from themold cavity.

[0062] The shell portions 15A, 15B can then be closed again and returnto the supply 50S. The shell portions may remain open for a period oftime to allow cleansing or sterilization of the internal mold cavitythat may be located in a second processing region (not shown) along aportion of the travel path. The sterilization or cleansing may becarried out automatically by directing the travel path to extend throughsuch a processing region.

[0063] In certain embodiments, the travel path and each respective shell15M of the mold assembly 15′ can be sized and configured to produce twoproducts per cycle. That is, the system 10 can include a second fillingstation that is located after location 2, and the shells 15M can bemated again and directed to travel through a separate processing region,then configured to open up to release a second product prior to location1 (not shown). Thus, the shells can mate together to close and opentwice along a single cycle of their travel in the travel path 15P.

[0064] As shown in FIG. 1D, the mated shell 15M includes at least oneport 17 that is in fluid communication with the internal mold cavity. Asbefore, a filling nozzle 50N can engage with the port 17 to disperse theemulsion 50E therein. Multiple filling nozzles can be used and each orselected matable shells 15M can include a plurality of filling ports(not shown). The plurality of ports 17 may be disposed at spaced apartlocations along the shell. The port 17 may be formed on the bottom,side, or top of the shell.

[0065]FIG. 2A illustrates the mold assembly 15 with the respective moldportions being configured one above the other. The nozzle 50N isillustrated in both FIGS. 2A and 3A as spaced apart from the shell withbroken line leading edges for a clearer illustration of the flowableemulsion 50E. FIG. 2B illustrates axially extending opposing side seamsassociated with the traveling mold cavities defined by the shellconfiguration shown in FIG. 2A. FIG. 3A illustrates a side-to-sideconfiguration of matable shell portions 15A, 15B, with opposing top andbottom axially extending seams of traveling mold cavities.

[0066] FIGS. 4A-4C illustrate examples of different internal mold cavityconfigurations 15C. Because the present invention is not limited toproducing food items using casings, non-regular configurations (sideprofiles and/or cross-sectional profiles) can be produced. That is,although the mold may be configured to yield a cylindrical product witha substantially circular profile, other mold configurations may also beused. Each mold cavity 15C of the mated shells 15M can be configured todefine a three-dimensional molded product (the same or different inselected ones of the shells on the mold assembly 15). The mold or shellscan be formed of stainless steel (such as 316 stainless steel) or otherfood-compatible material. Suitable food-compatible coatings orlubricants may also be deposited onto the surfaces of the mold cavitiesto inhibit contact adherence thereto and promote ease of removal. Suchcoatings may be integral to the cavity material, or applied at desiredintervals from an exogenous source.

[0067]FIG. 12A is a schematic of a closed mold shell 15M with a centerparting line according to embodiments of the invention. FIGS. 12B and12C illustrate exemplary connections that allow separation of the twomold halves 15A, 15B shown in FIG. 12A. The mold cavity 15C can beoriented to open in an upward direction as shown. FIG. 13A is aschematic of a closed mold shell 15M with a center parting lineaccording to embodiments of the invention. FIGS. 13B and 13C illustrateexemplary connections that allow separation of the two mold halves 15A,15B shown in FIG. 13A. The mold cavity 15C can be oriented to open in adownward direction as shown. The mold components can be configured toseparate a desired distance to allow access to the interior of theshell. They can be configured to entirely separate (as shown in FIGS.1A-1C, 2A, 3A) or to remain attached. FIGS. 12B and 13B illustrate apartial angular separation and FIGS. 12C and 13C illustrate that theshells can be separated to at least about 180 degrees.

[0068] FIGS. 14A-14B are schematic illustrations of a multiple componentmold shell 15M that employs greater than two matable components, shownas three components, 15A, 15B, 15E according to certain embodiments ofthe present invention. FIGS. 15A-15B illustrates a multiple componentmold shell that employs four matable components, 15A, 15B, 15E, 15F.

[0069] FIGS. 16A-16C are schematic illustrations of examples of matingalignments of mold components or orientations of parting lines ofcomponents that can come together to define the enclosed cavity 15Caccording to embodiments of the present invention.

[0070] Turning back to FIGS. 4A-4C, the mold cavities may be such that asingle discrete product is produced for a single shell cavity 15C (FIG.4A), a plurality of object shapes can be produced within a single shellcavity 15C (FIG. 4B), or a plurality of adjacent shell cavities can beconfigured to produce a single object shape (FIG. 4C).

[0071] FIGS. 5A-5E illustrate that the mold cavities can be configuredto provide molded food product in non-conventional or irregularcross-sectional (and/or side sectional) shapes. FIG. 5A illustrates ablock shape (such as square or rectangular) 50 a. If molded in anelongate shell, this configuration would be similar to a bar (notshown). FIG. 5B illustrates a crescent shape molded food product 50 b.FIG. 5C illustrates a curvilinear or winged object 50 c, while FIG. 5Dillustrates a star shaped product 50 d. FIG. 5E illustrates a footballshape 50 e (that can be produced in the axial and/or transversedirection). Thus, the shell mold cavity 15C configuration can beselected to provide a non-circular cross-sectional product, a productwith an irregular complex or non-constant shape cross-sectional profile,and/or an irregular side profile with an elongate but non-cylindricalshape.

[0072]FIG. 6A illustrates that the inner wall or surface of respectiveshell cavities can include surface indicia 21 positioned thereon. Thesurface indicia 21 can be configured in a pattern corresponding to thesurface pattern desired to be formed into the externally viewablesurface of the molded food product. The surface indicia can be formed adesired depth into the outer surface of the product, depending on theconfiguration of the indicia in the cavity. As such, the surface indiciapattern 21 can be configured as a recessed female deformation pattern(FIG. 6A) or as a raised male deformation pattern (FIG. 6B). One or bothsides of the shell portions, 15A, 15B can include the same, different,or cooperating complementary indicia that together define a continuouspattern extending over the outer surface of the object 50. The depth orprojection distance of the surface indicia can be configured to providea sufficiently prominent transferred pattern formed onto the exterior ofthe food product as the emulsion flows into the mold cavity 15C andtakes on the molded shape of the object defined by the mold cavity 15Cas the food object 50 is moved along the predetermined travel path inthe food processing system. In certain embodiments, the surface indicia21 can comprise alphanumeric indicia. In particular embodiments, thesurface indicia can include a design shape, decorative pattern, orfigure, such as a product or company logo, mark, and the like. In otherembodiments, the inner wall of the cavity 15C can be configured toimpart a desired surface marking or texture, such as representing searedgrill marks, predetermined visually darker regions, and the like. Inparticular embodiments, the surface indicia 21 can be provided byrecessed wells (female deformations) that can hold a dye to allow forselective color application.

[0073]FIGS. 7A and 7B illustrate that the product 50 can be processed indifferent manners, each of which may generate a different distributionpattern of the emulsion to the molded product. FIGS. 7A and 7B eachillustrate a processing region thermal zone over the length of which theproduct undergoes the heating and molding into a structurally suitableshaped (non-flowable) product. FIG. 8 illustrates a similar variationusing a cooling source to produce the molded product 50. The darkershades rendered in the graduated shading shown in FIGS. 7A, 7B, and 8illustrate cooked, frozen, or increased density alterations in theemulsion 50E from its original flowable state.

[0074] Turning back to FIG. 1A, as discussed above, the processingregion 20 can include one or a plurality of different treatment zones orenvironments. In applications that cook or heat the product 50, thecooking, heating and/or cooling can be carried out by any suitableenergy generating means as discussed above, including, but not limitedto microwave, RF, UV light, laser energy, thermal energy (heating in aconventional convection or conduction oven or cooling of freezing inrefrigerators/freezers), radiation energy, and the like. As such, as theemulsion 50E in the shell 15M travels through the processing region 20,along the predetermined travel path, it can be heated for predeterminedtimes and temperatures.

[0075] In certain embodiments, as shown in FIG. 9A, the processingregion 20 comprises three different treatment zones: (a) an active ordistributed energy generating zone that is used to expose the foodemulsion to a desired thermal energy at a desired time versustemperature profile; (b) a thermal (equilibrium) holding zone where thetemperature of the product is held substantially constant; and (c) athermal cooling zone where the temperature of the product is reduced.FIGS. 9B-9D illustrate examples of different time versus temperatureprofiles of exemplary processing conditions corresponding to thedifferent processing regions. The temperature profile may correspond toa selected location in the product (such as a center region of theproduct to promote reliable cooking). Other temperature profiles,residence times, and the like, can be used depending on the application.

[0076]FIG. 9A illustrates that the product temperature is returned toambient temperature and the thermal holding zone can hold the emulsionat a substantially constant internal temperature. FIG. 9B illustratesthat the thermal holding zone may raise the internal temperature andthen lower the product temperature to a cooled or frozen refrigeratedtemperature (the line extending below the initial condition). FIG. 9Cillustrates that the thermal holding zone can allow the product toincrease in temperature and then hold a substantially constanttemperature for a desired time. FIG. 9D illustrates that the holdingzone may decrease the internal temperature before the product enters thecooling zone. The cooling zone in FIG. 9A may be non-active or non-forcecooled (fans or natural air cooling can be used) to return the productto ambient.

[0077]FIG. 9E illustrates that the last thermal zone may be anotherheating zone (top line) or a cooling zone (broken bottom line). Eachthermal region may increase (or decrease) the temperature and then holdthat temperature for a desired time. The top line indicates that thethermal temperature is increased in the initial portion of each thermalzone. Other heating and cooling cycles or operations may also be used.

[0078] In particular embodiments, the thermal heating zone and/or thethermal holding zone are configured to raise the internal temperature ofthe emulsion to a desired temperature for a desired time. For example,in certain embodiments, the processing region 20 can be configured toraise the internal temperature of the shell enclosed emulsion 50E sothat it reaches at least about 150 degrees Fahrenheit for apredetermined time. In particular embodiments, for meat emulsions, theproduct may be cooked to an internal temperature of about 158 degreesFahrenheit.

[0079] In other embodiments, the product 50 can be cooked and thenfrozen in preparation for shipment. The product should be structurallysufficient (such as after cooking but before freezing) so that theobject 50 can substantially withstand its molded shape when removed fromits molding shell. In yet other embodiments, the product 50 can bedirectly frozen without cooking (typically for food intended to be eatenin a frozen state).

[0080] In certain embodiments, the processing region 20 is configured toheat the emulsion with one or more microwave energy generators togenerate about 400-600 kW of microwave energy generated in the thermaldistribution region to cook the emulsion in the shells for predeterminedtimes and energy levels as the emulsion travels enclosed in the shellsalong the predetermined travel path. For example, five 100 kW generatorsoperating at about 85% efficiency can generate about 425 kW of microwaveenergy that can be directed to a certain (typically shielded) portion ofthe processing region 20.

[0081] In particular embodiments, the processing conditions can be setto introduce a simulated skin layer onto the outer surface of theemulsion before its release from the mold. That is relatively hot orhigh-energy applied to the outer perimeter can provide an increaseddensity or drier region relative to the inner portion of the resultantnon-flowable edible product. The depth or thickness, as well as thedensity or hardness of the skin layer can be adjusted by the processingconditions. The shell itself may be heated (or preheated) to applycontact heat that is localized at the outer surface. In otherembodiments, RF or microwave energy and the like can be used.

[0082] As shown in FIG. 10A, the system 10′ can include a plurality ofseparate traveling mold assemblies 15 ₁, 15 ₂, a respective one for eachdifferent production line. As shown, the mold assemblies 15 ₁, 15 ₂ canbe configured to travel through a common processing region 20. Thus,each production line can include shell portions 15A, 15B, withassociated travel paths 15P (if similar to the embodiment shown in FIG.1D) or, for corresponding pairs of paths 15P₁, 15P₂, as shown in FIG.10A, each producing a line of molded product. As such, the mold shells15M for each production line can be directed to travel through theprocessing region concurrently (using a processing region configured tosurround a plurality of production lines, with a shared heating, holdingand/or cooling region). Each line may be operated to yield the sameproduct in the same or different shapes or sizes, or different products.The system 10′ may include a central controller 30 that directs theoperation of a plurality of different energy sources 30 e. Thecontroller 30 can adjust the energy generated depending on the type ofproduct traveling in the processing region (such as the size of the mold(volume) and/or type of emulsion mixture in the mold). The energysources 30 e may be of the same type and operated to maintain ahomogenous or constant energy or temperature region in the processingregion. Alternatively, selected ones of the energy sources 30 e may beoperated to produce local “hot” or “cold” spots or a graduated heatingor cooling treatment zones as desired. FIG. 10A also illustrates thatthe temperature of the product can be raised from a first startingtemperature T₁ to a second cooked temperature, T₂ that is at least aboutdouble the starting temperature measured in degrees Fahrenheit. Asshown, the food emulsion may start at a temperature of about 50 degreesFahrenheit and be processed to reach a temperature of about 158 degreesFahrenheit.

[0083]FIG. 10A illustrates that the lines may be oriented one above theother and directed to flow in a substantially horizontal throughputconfiguration, with the shell portions 15A, 15B, traveling in ahorizontal forward and rearward directions for a major portion of thelength of the travel path 15 p ₁, 15 p ₂. FIG. 10B illustrates anexample of two lines of mold assemblies 15 ₁, 15 ₂ used to move theproduct through the processing region. FIG. 10C illustrates that thelines may be configured in side-by-side alignment and oriented to movein a vertical throughput configuration, with the shell portions 15A, 15Btraveling in a vertically upward or downward direction for a majorportion of the length of the travel path 15 p ₁, 15 p ₂.

[0084]FIG. 11A illustrates a system 10″ with a nested configuration ofthree production lines 100, 101, 102, using two mold assemblies 15 ₁, 15₂ that are spaced apart in cooperating alignment to define theintermediate production line 101. Thus, the intermediate production line101 employs mold shells provided from the upper and lower moldassemblies 15 ₁, 15 ₂. The intermediate line 101 produces the foodproduct 50 in an opposing direction from the upper and lower lines 100,102 (or opposing side lines 100, 102 as shown in FIG. 11C). Thus, thesystem 10″ can provide three sets of mated traveling mold shells usingtwo different mold assemblies 15 ₁, 15 ₂ (similar to that shown in FIGS.10A-10C). FIG. 11C again illustrates that the lines 100-102 may beoperated in a vertical orientation.

[0085] In certain embodiments, the devices and methods of the presentinvention can be used to continually automatically produce a series ofdiscrete products 50 held in a corresponding series of endlesslytraveling mold shells that meet to define an encased cavity that isconfigured to receive the flowable product and mold it to a desiredshape defined by the mold cavity. In particular embodiments, thetraveling mold shells are opposing “caterpillar” molds that meet andseparate to travel separate aligned paths. The term “continually” meansthat the apparatus can be configured to expel or provide a series ofproducts substantially constantly over a production shift or batch.

[0086] In certain embodiments, the systems 10, 10′, 10″ can beconfigured to process individual shells with emulsions therein toproduct at a rate of about at least 1 fps.

[0087] In particular embodiments, certain systems contemplated by thepresent invention may produce over about 200 linear feet of elongateconsumable meat product in less than about five minutes. Such anautomated process may be employed without requiring direct manual laborto form or remove the products from the shell, and, hence, may beparticularly suitable for mass-production environments. In otherparticular embodiments, the system 10, 10′, 10″ may be configured withone or more production lines running at a rate of about 1, fps,typically at least about 3 fps or more, such as about 5 fps, to produceabout 5,000-10,000 lbs/hour of the same or different food products usingthe matable shells contemplated by the present invention.

[0088] In certain embodiments, a food grade or food compatible film orcoating can be deposited on the inner surface of the shell portions 15A,15B (in the mold cavity) to inhibit the food product from adheringthereto during processing, thereby promoting its release. The shellportions 15A, 15B may be formed of a stainless steel material or othersuitable food production grade material that can be sterilized andcleansed. The materials and coatings can be selected to allow the shellsto be re-used over many production cycles.

[0089] The thickness and type of materials selected to form the shellsand/or the mold cavities that contact and hold the food material maydepend on the production environments that the food will be exposed toas well as the configuration (type and size) of the food beingprocessed. For example, light, microwave, thermal (heat and/or cooling),and RF energies may have different demands that promote uniform andreliable transfer of the treatment to the food product and/or suitableexposures and exposure rates in an aesthetically acceptable manner.

[0090] In certain embodiments, one of the shell portions 15A, 15B may beconfigured with an optically viewable window for optical assessment ofthe state of the product.

[0091] The systems 10, 10′, 10″ may be configured to cook, freeze,smoke, cure, pickle, partially dehydrate, or otherwise process the food50 as it moves through the processing region(s) 20.

[0092] The foregoing is illustrative of the present invention and is notto be construed as limiting thereof. Although a few exemplaryembodiments of this invention have been described, those skilled in theart will readily appreciate that many modifications are possible in theexemplary embodiments without materially departing from the novelteachings and advantages of this invention. Accordingly, all suchmodifications are intended to be included within the scope of thisinvention as defined in the claims. In the claims, means-plus-functionclauses, where used, are intended to cover the structures describedherein as performing the recited function and not only structuralequivalents but also equivalent structures. Therefore, it is to beunderstood that the foregoing is illustrative of the present inventionand is not to be construed as limited to the specific embodimentsdisclosed, and that modifications to the disclosed embodiments, as wellas other embodiments, are intended to be included within the scope ofthe appended claims. The invention is defined by the following claims,with equivalents of the claims to be included therein.

That which is claimed is:
 1. A method for producing food products,comprising: providing a series of shells, the shells having sufficientstructural rigidity to define an enclosed cavity space of predeterminedsubstantially constant size and shape; injecting a quantity of flowablefood emulsion into the shells in serial order; moving the shells forwardalong a predetermined travel path with the emulsion in the enclosedcavities; exposing the emulsion in the shells to predeterminedprocessing conditions that alter the emulsion held in the respectiveshells to a non-flowable edible food product having the molded shape oftheir respective shell cavities; and then releasing the non-flowablefood products from their respective shells.
 2. A method according toclaim 1, wherein the moving step is substantially constant, and whereinthe shells are aligned and configured to travel along one or moreendless paths associated with the predetermined travel path.
 3. A methodaccording to claim 2, wherein the shells include matable first andsecond shell portions that mate together to encase the flowable emulsionand separate to release the non-flowable food product.
 4. A methodaccording to claim 3, wherein the first and second shell portions areconfigured to serially travel in the predetermined travel path so as tomate together at a first location and travel together for a firstportion of the predetermined travel path, then separate at a secondlocation and travel separately and spaced apart for a second portion ofthe predetermined travel path, the second portion of the travel pathbeing configured to return to the first and second shell portions to thefirst location.
 5. A method according to claim 1, wherein the shellshave opposing top and bottom portions and opposing end portions, andwherein the step of injecting is carried out by injecting the emulsioninto an end portion of the shell.
 6. A method according to claim 1,wherein the shells have opposing top and bottom portions and opposingend portions, and wherein the step of injecting is carried out byinjecting the emulsion into at least one of the top or bottom portion ofthe shell.
 7. A method according to claim 1, wherein the step of movingcomprises moving the enclosed shell with the emulsion in a substantiallyvertical orientation along at least a portion of the predeterminedtravel path.
 8. A method according to claim 1, wherein the step ofmoving comprises moving the enclosed shell with the emulsion in asubstantially horizontal orientation along at least a portion of thepredetermined travel path.
 9. A method according to claim 1, furthercomprising injecting the emulsion with sufficient pressure that surfaceindicia positioned on the inner surface of the respective shell cavitiesimprints a desired pattern onto the exterior of the food product as theemulsion is moved along the predetermined travel path during theexposing step.
 10. A method according to claim 9, wherein the surfaceindicia comprises alphanumeric indicia.
 11. A method according to claim9, wherein the surface indicia comprises a logo.
 12. A method accordingto claim 1, wherein the step of molding is carried out to provide aproduct with an irregular cross-sectional profile.
 13. A methodaccording to claim 1 ,wherein the step of molding is carried out toprovide a product with a non-circular cross-sectional profile.
 14. Amethod according to claim 1, wherein the step of molding is carried outto provide a product with an irregular side profile.
 15. A methodaccording to claim 1, wherein the step of molding is carried out toprovide a product with a non-cylindrical shape.
 16. A method accordingto claim 1, wherein the exposing step comprises heating the emulsion forpredetermined times and temperatures as the emulsion travels enclosed inthe shells along the predetermined travel path.
 17. A method accordingto claim 16, wherein the heating step is carried out to raise theinternal temperature of the enclosed emulsion to at least about 150degrees F.
 18. A method according to claim 1, wherein the exposing stepcomprises cooling the emulsion for predetermined times and temperaturesas the emulsion travels enclosed in the shells along the predeterminedtravel path.
 19. A method according to claim 1, wherein the exposingstep comprises directing microwave energy at the emulsion in the shellsfor predetermined times and energy levels as the emulsion travelsenclosed in the shells along the predetermined travel path.
 20. A methodaccording to claim 1, wherein the exposing step comprises directing RFenergy at the emulsion in the shells for predetermined times and energylevels as the emulsion travels enclosed in the shells along thepredetermined travel path.
 21. A method according to claim 1, whereinthe injecting is carried out at a flow rate of at least about 1 fps. 22.A method according to claim 1, wherein the injecting step is carried outto at a sufficient pressure to cause the emulsion to fill the volume ofthe cavity.
 23. A method according to claim 1, wherein the flowableemulsion in the injecting step is a flowable meat based emulsion havingan associated viscosity.
 24. A method according to claim 1, wherein theemulsion comprises at least one type of meat.
 25. A method according toclaim 24, wherein the emulsion comprises at least one of pork, beef,lamb, veal, and poultry and/or analogs or derivatives thereof.
 26. Amethod according to claim 24, wherein the emulsion comprises groundpork, ground beef and ground veal and/or selected ones or combinationsof analogs or derivatives thereof.
 27. A method according to claim 1,wherein the non-flowable edible food product comprises hot dogs.
 28. Amethod according to claim 1, wherein the non-flowable edible foodproduct comprises sausages.
 29. A method according to claim 1, furthercomprising introducing a skin onto the outer surface of the emulsionduring said exposing step prior to said releasing step.
 30. A foodproduction system, comprising: a plurality of shells arranged in anendless travel path, the shells configured with at least one emulsionentry port and first and second detachably matable shell portions, theshell portions are configured to mate together to provide an enclosedcavity having a predetermined configuration, and to separate to allowaccess to the interior of the cavity; a flowable food emulsion sourcecomprising a flow nozzle that is configured to inject emulsion into theshells; a transport system that is configured to move the plurality ofshells along the endless travel path so that each shell is positioned incooperating alignment with the flowable food emulsion source at leastonce during each cycle of travel along the endless travel path; and aprocessing region operably associated with the endless travel path sothat, in operation, the processing region exposes the emulsion in theattached shells to a predetermined condition as the shells travel alonga portion of the endless travel path.
 31. A system according to claim30, wherein the shells are aligned and adjacent ones are closely spaced,so that, between adjacent shells, a forward portion of the adjacentrearward shell abuts the rearward portion of the adjacent forward shell.32. A system according to claim 30, wherein the shells are held inspaced apart alignment and synchronously travel at a desired rate alongthe endless path.
 33. A system according to claim 30, wherein the shellscomprise opposing end portions and opposing side portions, and whereinthe at least one emulsion port is disposed on an end portion of theshell.
 34. A system according to claim 30, wherein the shells compriseopposing end portions and opposing side portions, and wherein the atleast one emulsion port is disposed on a side portion of the shell. 35.A system according to claim 30, wherein the shells and transport systemare configured to move the shells substantially vertically along atleast a portion of the processing region.
 36. A system according toclaim 30, wherein the shells and transport system are configured to movethe shells substantially horizontally along at least a portion of theprocessing region.
 37. A system according to claim 30, wherein thesystem defines a food travel path that is a subset of the shell endlesstravel path and extends between spaced apart first and second locationsalong the endless travel path, and wherein the first and second shellportions are configured to serially travel so as to mate together at thefirst location along the endless travel path and travel together for afirst portion of the endless travel path, then separate at a secondlocation downstream of the first location, and then travel separatelyand spaced apart for a second portion of the endless travel path, thesecond portion of the endless travel path being configured to return thefirst and second shell portions to the first location, the firstlocation of the food travel path being proximate the food emulsionsource.
 38. A system according to claim 30, wherein the endless pathcomprises a first shell portion endless path that is a first loop and asecond shell portion endless path that is a second loop.
 39. A systemaccording to claim 38, wherein the first loop is disposed above thesecond loop.
 40. A system according to claim 38, wherein the first loopis transversely spaced from the second loop.
 41. A system according toclaim 38, wherein the first and second loops are substantiallyvertically oriented so that the shells travel a major portion of theendless path in a vertical orientation both downward and upward.
 42. Asystem according to claim 38, wherein the first and second loops aresubstantially horizontally oriented so that the shells travel a majorportion of the endless path in a horizontal orientation.
 43. A systemaccording to claim 30, further comprising: a second plurality of shellsarranged in a second endless travel path, the shells configured with atleast one emulsion entry port and first and second detachably matableshell portions, the shell portions are configured to mate together toprovide an enclosed cavity having a predetermined configuration, and toseparate to allow access to the interior of the cavity; a secondflowable food emulsion source comprising a flow nozzle that isconfigured to inject a quantity of emulsion into the shells; and asecond transport system that is configured to move the second pluralityof shells along the endless travel path so that each shell is positionedin cooperating alignment with the food emulsion source at least onceduring each cycle of travel along the endless travel path and travelsthrough the processing region so that the emulsion in the attached firstand second plurality of shells are exposed to predetermined conditionsas the first and second shells travel along their respective endlesstravel paths.
 44. A system according to claim 30, wherein the transportsystem is configured to move the shells at an adjustable speed.
 45. Asystem according to claim 30, wherein the inner surfaces of the shellscomprise deformations formed thereon, the deformations corresponding tosurface indicia or texture that is to be formed onto the exterior of thefood product during operation.
 46. A system according to claim 30,wherein the shell cavities have an elongate shape.
 47. A systemaccording to claim 30, wherein when the first and second shell portionsmate, the respective shell cavities define an irregular cross-sectionalmold configuration that, in operation, molds the food product into ashape having an irregular cross-sectional profile.
 48. A systemaccording to claim 30, wherein when the first and second shell portionsmate, the respective shell cavities define an irregular side profilemold configuration that, in operation, molds the food product into ashape having an irregular side profile.
 49. A system according to claim30, wherein the inner surfaces of the shells comprise raised or deformedregions corresponding to surface indicia patterns positioned thereon, sothat, in operation, the pattern is applied to the outer surface of thefood product.
 50. A system according to claim 49, wherein the surfaceindicia pattern is alphanumeric.
 51. A system according to claim 49,wherein the surface indicia pattern is in the shape of a logo design.52. A system according to claim 30, wherein the shell cavities areconfigured with a non-circular cross-sectional profile.
 53. A systemaccording to claim 30, wherein the shell cavities are non-cylindrical.54. A system according to claim 30, wherein the processing regioncomprises an oven for heating the emulsion in the shells forpredetermined times and temperatures as the emulsion travels enclosed inthe shells along a food travel path.
 55. A system according to claim 54,wherein the oven is configured to generate sufficient energy and therespective shell residence time therein is such that the internaltemperature of the shell enclosed emulsion rises to at least about 150degrees F.
 56. A system according to claim 55, wherein the processingregion further comprises a cooler that cools the emulsion in the shellsfor a predetermined time.
 57. A system according to claim 30, whereinthe processing region comprises a microwave energy source that isconfigured to direct microwave energy at the emulsion in the shells fora predetermined time and energy level.
 58. A system according to claim30, wherein the processing region comprises an RF energy source that isconfigured to direct RF energy at the emulsion in the shells for apredetermined time and energy level.
 59. A system according to claim 30,wherein the emulsion source flow nozzle is configured to inject theflowable emulsion into the shell entry port at a flow rate of a leastabout 1 fps.
 60. A system according to claim 30, wherein the flow nozzleis configured to inject the flowable emulsion with sufficient pressureto cause the emulsion to substantially fill the volume of the respectivecavity.
 61. A system according to claim 30, wherein the flowableemulsion is formulated to produce a shaped burger.
 62. A systemaccording to claim 30, wherein the flowable emulsion comprises at leastone meat, meat analog, or meat derivative.
 63. A system according toclaim 62, wherein the emulsion comprises at least one of pork, beef,veal, and/or poultry.
 64. A system according to claim 63, wherein theemulsion comprises ground pork, ground beef and ground veal.
 65. Asystem according to claim 30, wherein the emulsion is configured withingredients to provide hot dogs as the resultant food product.
 66. Asystem according to claim 30, wherein the emulsion is configured withingredients to provide sausages as the resultant food product.
 67. Asystem according to claim 30, wherein, in operation, downstream of theflowable emulsion source, the mated shells with the enclosed emulsionare transported through the processing region so that the emulsiontransforms from a flowable state to a non-flowable food product havingthe shape of the shell cavity.
 68. A system according to claim 67,wherein, in operation, an outer layer of skin having an increaseddensity relative to the underlying food material is formed onto the foodproduct based on processing conditions generated in the processingregion.
 69. A system according to claim 68, wherein the skin layer isgenerated by at least one of the residence time of the respective shellsin the processing region, the type of processing energy employed in theprocessing region, the energy level generated in the processing region,and/or the temperature that the outer region of the emulsion is exposedto while in the shell cavity.
 70. A method for producing food products,comprising: means for providing a series of shells, the shells havingsufficient structural rigidity to define an enclosed cavity space ofpredetermined substantially constant size and shape; means for injectinga quantity of flowable food emulsion into the shells in serial order;means for moving the shells forward along a predetermined travel pathwith the emulsion in the enclosed cavities; means for exposing theemulsion in the shells to predetermined processing conditions that alterthe emulsion held in the respective shells to a non-flowable edible foodproduct having the molded shape of their respective shell cavities; andthen means for releasing the non-flowable food products from theirrespective shells.
 71. A mold assembly for the production of casinglessfoodstuffs, comprising: a first mold portion having a first inner cavityregion; a second mold portion having a second inner cavity region, thefirst and second mold portions being detachably matable so that thefirst and second inner cavity regions align to define a mold cavity witha predetermined three dimensional foodstuff mold shape; and a transportsystem operably associated with the first and second mold portions thatautomatically moves the first and second mold portions in respectiveendless paths that allows the first and second mold portions to mate andthen separate as they travel along their respective endless paths.
 72. Amold assembly according to claim 71, wherein at least one of the firstand second inner cavity regions comprises a surface indicia patternthat, in operation, transfers a corresponding surface indicia patternonto the outer layer of a molded foodstuff.
 73. A mold assemblyaccording to claim 72, further comprising a flowable food emulsiondisposed in the mold cavity after the first and second mold portions aremated.